System and method for repairing a component made out of a plastic

Abstract

A system for repairing a component made out of a plastic comprises a frame, a multiaxial guide device coupled with the frame, with a tool holder arranged thereon, an optical acquisition device, a processing device, and a plastic deposition device. The frame comprises a mounting device for retaining the frame on a component surface. The optical acquisition device, the processing device and the plastic deposition device are arranged on the tool holder. The optical acquisition device is set up to optically inspect a surface area of the component lying in proximity to the frame from at least one viewing angle, so as to acquire the spatial structure of the surface area. The processing device is set up to remove material of a damaged area from the component for generating a base surface with a desired structure and boundary edges.

Claims

1. A system for repairing a component made out of a plastic, comprising: a frame comprising a mounting device to retain the frame on a surface of the component, a multiaxial guide device coupled with the frame, with a tool holder arranged thereon, the multiaxial guide device controllable to move the tool holder relative to the frame, an optical acquisition device arranged on the tool holder and configured to optically inspect a surface of the component lying in proximity to the frame from at least one viewing angle to acquire a spatial structure of the surface area, a processing device arranged on the tool holder and configured to remove material of a damaged area from the component, wherein movement of the tool holder is controlled such that the processing device generates a base surface with a desired structure and boundary edges, a plastic deposition device arranged on the tool holder and configured to apply plastic onto the base surface in layers, at least until a repair layer generated by the applied plastic abuts flush against an adjacent component surface in an undamaged area, the plastic deposition device comprising a deposition nozzle through which the plastic is deposited, the deposition nozzle pivotable around an axis perpendicular to a deposition direction of the deposition nozzle, and a fiber deposition device arranged on the tool holder and configured to deposit reinforcing fibers onto the base surface such that reinforcing fibers deposited from the fiber deposition device cooperate with plastic deposited from the plastic deposition device, the fiber deposition device rotatable around at least one axis perpendicular to the deposition direction of the deposition nozzle.

2. The system of claim 1, wherein plastic is deposited through the deposition nozzle from a reservoir.

3. The system of claim 1, wherein the plastic deposition device is set up to deposit a plastic mixed with reinforcing fibers.

4. The system of claim 1, wherein the plastic deposition device is set up to mix fibers from a fiber reservoir into a plastic stream to be deposited.

5. The system of claim 1, wherein the plastic deposition device comprises a heating device and a reservoir for a thermoplastic plastic, wherein the plastic is liquefiable for deposition by heating with the heating device.

6. The system of claim 1, further comprising a plasma nozzle, which is set up to activate the base surface in an atmospheric pressure plasma method.

7. The system of claim 1, further comprising a testing device having at least one sensor and situated on the tool holder for the non-destructive material examination of the repair layer and adjacent areas.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements:

(2) Additional features, advantages and possible applications may be gleaned from the following description of the exemplary embodiments and the figures. All described and/or graphically illustrated features here comprise the subject matter, whether taken in isolation or in any combination desired, even independently of their composition in the individual claims or back references thereto. Furthermore, identical reference numbers on the figures stand for the same or similar objects.

(3) FIG. 1 shows a system for repairing a component made out of a plastic.

(4) FIG. 2A-FIG. 2H show consecutive procedural steps of a method for repairing a component made out of a plastic.

(5) FIG. 3 shows a simplified spatial view of the system to provide a better understanding.

DETAILED DESCRIPTION

(6) The following detailed description is merely exemplary in nature and is not intended to limit the disclosed embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background detailed description.

(7) FIG. 1 shows the essential features of a system 2 for repairing a component made out of a plastic, wherein the system comprises a frame 4, a multiaxial guide device 6 coupled with the frame 4, and a tool holder 8 arranged thereon, which accommodates an optical acquisition device 10 with two optical sensors 12. The tool holder 8 further carries a plastic deposition device 14, which has a deposition nozzle 16 and a fiber deposition device 18 that is separate or coupled with the plastic deposition device 14, and further may be rotated around at least one axis perpendicular to a deposition direction 20 of the nozzle 16.

(8) Further arranged on the tool holder 8 is a processing device 22 that may also be moved in the vertical direction to control the cutting depth relative to the frame 4.

(9) The frame 4 also comprises a mounting device 24 with suction cups 26, which are set up to retain the frame 4 on the surface of the component. As an additional option, it would be conceivable to move the system 2 on the component surface by selectively activating and moving the individual suction cups 26, so as to process two or more damaged locations in succession, for example. The combination of these features makes it possible to implement the method, as shown on the following FIG. 2A to 2H.

(10) In FIG. 2A, the system is placed on a component 28 that comprises a damaged area 30. The latter extends from a surface 32 of the component 28 into its material. By placing the system 2 on the component 28, the suction cups 26 may adhere to the surface 32, so that the actual procedural steps for repairing the damaged area 30 may be initiated.

(11) On FIG. 2B, the optical sensors 12 of the optical acquisition device 10 scan the structure of the damaged area 30, so that a control unit (not shown) is provided with information about the structural scope of the damaged area 30, and generate a 3D model or an approximation of the latter, for example. The optical sensors may here each assume one or more viewing angles, and scan the damaged area 30 along a striped or other type of pattern until enough data have been gathered to sufficiently acquire the structure of the damaged area.

(12) In order to acquire the structure, the tool holder 8 may be moved along the frame 4 toward the component surface 32, so as to establish a corresponding perspective or a favorable distance between the acquisition units 12 and component surface 32. Moving the tool holder 8 allows the acquisition device 10 to analyze the entire area of the component 28 enveloped by the frame.

(13) As shown on FIG. 2C, the processing device 22 may then process the damaged area 30 in such a way as to yield a smooth or homogeneous base surface. For this purpose, the tool holder 8 may be moved parallel to the component surface 32, and the processing device 22 may preferably be moved perpendicularly thereto.

(14) As shown on FIG. 2D, a homogeneous base surface 34 is then generated, which comprises defined expansions both parallel to the component surface 32 and perpendicularly thereto. The base surface 34 may comprise stepped, outwardly expanding boundary edges 40.

(15) The structure obtained in this way is then examined once again by the optical acquisition device 10, so that an exact spatial image of the base surface 34 may be generated. This is depicted on FIG. 2E.

(16) The plastic deposition device 14 then deposits layers of plastic onto the base surface 34, as depicted in FIG. 2F, and preferably fills the latter layer by layer. For this purpose, the tool holder 8 is moved over the entire base surface 34 in regular webs as a function of the acquired model of the base surface 34, and the plastic deposition device periodically deposits plastic, either continuously or depending on how the webs are interrupted.

(17) As shown in one section on a magnified scale, fibers 36 may be applied at the same time that the plastic is deposited. These are then preferably embedded into the plastic 38 in a traveling motion, thereby giving rise to a fiber-reinforced plastic, which abuts flush against the boundary edges 40 of the base surface.

(18) The surface of the repair layer 42 may then be processed once more by the processing device 22, thereby resulting in a homogeneous surface. This is depicted on FIG. 2G. Prior to this step, the structure may be subjected to another optical acquisition.

(19) The system 2 may then be removed again, as depicted on FIG. 2H. It may further be advantageous for the system 2 to comprise an ultrasound sensor (not shown), which examines both the repair layer and transitions between the repair layer and component surface 32. This makes it possible to gain knowledge about the present quality of the repair.

(20) As an alternative thereto, such an ultrasound examination may also be performed using separate devices.

(21) Finally, FIG. 3 shows a somewhat simplified, spatial view of the system 2 with an exemplarily rectangular frame 4, on which the guide device 6 is mounted. To this end, two opposing frame elements 44 each comprise a guide rail 46, for example, which may be designed as a groove in the frame elements 44, or as a separate, superimposed guide rail 46. Guided therein is a retaining arm 48, to which the tool holder 8 is fastened, and may be moved by means of driving devices (not shown) perpendicular to the plane spanned by the frame 4, i.e., in the z-direction of the indicated coordinate system, on the retaining arm 48, and along its extension, i.e., in the y-direction. By arranging another driving device (not shown) on the frame 4, a traveling motion takes place along the guide rails 46, i.e., in the x-direction of the indicated coordinate system.

(22) Of course, the frame 4 may also comprise a completely different structural design. However, it is advantageous that the frame 4 be stiff enough to allow a high return accuracy, i.e., reproducibility of the positions reached by the tool holder 8, so that the contours determined via optical acquisition may be precisely used for controlling the application of plastic.

(23) In addition, let it be noted that comprise does not rule out any other elements or steps, and that a or an do not preclude a plurality. Let it further be noted that features described with reference to one of the above exemplary embodiments may also be used in combination with other features of other exemplary embodiments described above. Reference numbers in the claims are not to be construed as a limitation.

(24) While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the embodiment in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the embodiment as set forth in the appended claims and their legal equivalents.